Tire Building Plant Segmented Paths for Drum Exchange
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Solution Overview
Problem
The management of forming drums and auxiliary support elements in tire building lines is complex, leading to increased building times, resource usage, and plant bulk, especially when using semifinished products stored in storage areas, which affects layout, production, and flexibility.
Innovation Solution
Implementing a method and plant with separate building paths for forming drums with and without auxiliary support elements, including an exchange station where forming drums are decoupled from auxiliary support elements and replaced with new ones, allowing for efficient transfer and processing, enabling simultaneous building of multiple tires with different geometric characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If forming drums are continuously coupled with auxiliary support elements in the same building line, then tire building can proceed without interruption, but the management complexity and plant bulk increase significantly
Solution Approach 1:
The building line is divided into two separate paths: a first building path for forming drums coupled with auxiliary support elements, and a second building path for forming drums without auxiliary support elements. This segmentation allows independent management of each path, reducing overall system complexity while maintaining continuous production capability.
Solution Approach 2:
An exchange station is introduced as an intermediary between the two building paths. This exchange station facilitates the transfer of forming drums from one path to the other, enabling seamless continuation of production while simplifying the management of auxiliary support elements through centralized coupling and decoupling operations.
2Productivity
If auxiliary support elements are used for all forming drums, then tire building efficiency is maintained, but processing dead times increase due to repeated coupling and decoupling operations
Solution Approach 1:
Auxiliary support elements are coupled to forming drums in advance during the first building path before the drums enter the second building path. This preliminary action eliminates the need for repeated coupling and decoupling operations, reducing processing dead times while maintaining building efficiency.
Solution Approach 2:
The system dynamically assigns forming drums to different building paths based on production requirements. By allowing forming drums to be decoupled from auxiliary support elements at the exchange station, the system flexibly adapts to different tire building needs while minimizing idle time through continuous operation of both paths.
3Ease of manufacture
If a single building line is used for all tire building operations, then plant layout is simplified, but flexibility for producing tires with different geometric characteristics is reduced
Solution Approach 1:
The building line is segmented into two distinct paths with specialized functions. The first path handles forming drums with auxiliary support elements for specific tire types, while the second path handles forming drums without auxiliary support elements for other tire types. This segmentation provides flexibility for producing tires with different geometric characteristics while maintaining a compact plant layout through the shared exchange station.
Solution Approach 2:
The exchange station serves multiple functions: it acts as a transfer point between building paths, a coupling/decoupling station for auxiliary support elements, and a buffer for managing forming drum flow. This multi-functionality enables the plant to handle diverse tire production requirements within a simplified layout.
Data Source
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AI summary
A first ("A") and a second building path ("B") are defined along a carcass building line (12). A forming drum (13) coupled to a pair of auxiliary support elements (22) is moved by means of a conveyor (21) along the first building path ("A"), while forming drums (13) decoupled from the auxiliary support elements (22) are moved along the second building path ("B"). In an exchange station (19), the forming drum (13) coming from the first building path ("A") is transferred to the second building path ("B") in the absence of the auxiliary support elements (22), and a forming drum (13) coming from the second building path ("B") is transferred to the exchange station (19), in order to then be coupled to the same pair of auxiliary support elements ( 22 ).